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United States Patent |
5,616,899
|
Recigno
|
April 1, 1997
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System for managing cases in dental laboratory
Abstract
A system for managing the processing of dental appliances being fabricated
in a dental laboratory. The fabrication of such appliances is achieved in
a series of iterations, the first of the iterations occurring upon receipt
of a prescription from the doctor for fabricating the appliance therefrom.
Subsequent iterations occur upon return of the appliance by the doctor to
the laboratory for additional processing. The system comprises a digital
processing means, a data collection means, and data storage means. The
data collection means is arranged to collect process related data
associated with each iteration. The data storage means is arranged to
store said process related data associated with each iteration while
preserving previously stored data associated with prior iterations. Data
indicative of the history of the fabrication of the appliance through all
of the iterations is available to the operator of the laboratory for
analysis and the effective and efficient management of the laboratory.
Inventors:
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Recigno; David T. (Willow Grove, PA)
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Assignee:
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Recigno Laboratories, Inc. (Willow Grove, PA)
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Appl. No.:
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461283 |
Filed:
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June 5, 1995 |
Current U.S. Class: |
235/375; 700/95 |
Intern'l Class: |
G06F 017/00 |
Field of Search: |
235/375,376
364/401,402,468
|
References Cited
U.S. Patent Documents
5142128 | Aug., 1992 | Perkin et al. | 235/375.
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5376777 | Dec., 1994 | Kamei et al. | 235/375.
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5491637 | Feb., 1996 | Kramer et al. | 235/375.
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Other References
"Catalog of Computer Software and Hardware", pp. 15-17, May 1995 edition of
LMT (Lab Management Today), published by Dental Lab Publications, Inc.
|
Primary Examiner: Hajec; Donald T.
Assistant Examiner: Filipek; Jeffrey R.
Attorney, Agent or Firm: Caesar, Rivise, Bernstein, Cohen & Pokotilow, Ltd.
Claims
I claim:
1. A system for managing the processing of dental appliances being
fabricated in a dental laboratory wherein the fabrication of such
appliances is achieved in iterations, with the first of said iterations
comprising receipt of a prescription from the doctor for fabricating the
appliance therefrom, and with subsequent iterations comprising return of
the appliance by the doctor to the laboratory for additional processing,
said system comprises digital processing means, a data collection means,
and data storage means, said data collection means being arranged to
collect process related data associated with each iteration, data storage
means being arranged to store said process related data associated with
each iteration while preserving previously stored data associated with
prior iterations, whereupon data indicative of the history of the
fabrication of the appliance through all of the iterations is available to
the operator of the laboratory for analysis and the effective and
efficient management of the laboratory, said data collection means
comprising a bar-code scanner and wherein said system additionally
comprises a work ticket, a prescription return form and a shipping label,
each having at least one bar-code label containing said process related
data and readable by said bar-code scanner.
2. The system of claim 1 wherein said bar-code label of said work ticket
contains information identifying the workstations at which processing
steps are to be performed.
3. The system of claim 1 wherein said bar-code label of said prescription
return form contains doctor identification, case identification, and
prescription identification.
4. The system of claim 1 wherein said bar-code label of said shipping label
contains a doctor's identification and shipping address.
5. The system of claim 1 wherein said system additionally comprises a bar
code printer and wherein said work ticket, prescription return form and
shipping label are printed on said bar-code printer.
6. The system of claim 5 wherein said bar-code printer is a laser printer.
7. The system of claim 5 wherein said bar-code printer is a thermal
printer.
8. The system of claim 1 wherein the dental laboratory includes a plurality
of divisions.
9. The system of claim 1 wherein said bar-code scanner is hand-holdable.
10. The system of claim 9 wherein said bar-code scanner is portable.
11. The system of claim 1 wherein said digital processing means comprises a
server workstation and plural client workstations, said client
workstations being located within selected departments of the dental
laboratory.
12. The system of claim 11 wherein said data collection means comprises a
bar-code scanner capable of serving said plural client work stations.
13. The system of claim 12 wherein said bar-code scanner is capable of
processing data in batch mode.
14. The system of claim 12 wherein said bar-code scanner is capable of
processing data in single case mode.
15. The system of claim 12 wherein said bar-code scanner contains a
microprocessor and memory for storing said process related data.
16. The system of claim 11 wherein said system additionally comprises a
network, said network comprising a communication channel connecting said
server workstation with at least one said client workstation.
17. The system of claim 16 wherein said client workstation is a
microcomputer.
18. The system of claim 12 wherein said server workstation is a
microcomputer.
19. The system of claim 1 wherein said data storage means comprises a
relational database.
Description
BACKGROUND OF THE INVENTION
This invention relates to systems for managing and analyzing the operation
of a dental laboratory engaged in the fabrication of dental appliances,
e.g., dentures, partial dentures, implants, crowns, bridges, and
mouthguards at the prescription of a dentist to increase efficiency and
maximize profitability.
Typically, a dental laboratory constructs any one of a variety of
artificial dental structures or appliances, i.e., dentures, partial
dentures, crowns and bridges, which serve to replace a patient's lost
dentition in an aesthetically pleasing manner. These structures are
commonly referred to as "cases" during their fabrication in a dental
laboratory and are fabricated in accordance with a prescription provided
by the dentist.
There are several systems presently available in the marketplace that
automate certain aspects of the operation of a dental laboratory in the
fabrication of the dental appliances or cases. However, these prior art
systems leave much to be desired. Most importantly, these systems are
concerned primarily with the record keeping functions of the dental
laboratory and often do little more than automate the generation of
invoices sent to the dentists prescribing the appliances. Because these
presently available systems are geared toward the limited functions of
record keeping, they are arranged to gather only the information relating
to a case that is necessary for generating bills.
These presently available systems do not provide a means for tracking cases
from pickup at the prescribing dentist's office through laboratory
production steps to delivery and invoicing. These systems do not provide a
means for keeping track of important historical information about cases
for the purpose of increasing efficiency in a dental laboratory. By
historical information it is meant all information relating to the
processing of a case from the time the case is originated in the dental
laboratory to the time of completion of the dental appliance. Typically,
under systems presently available, information relating to the processing
of a case is overwritten each time the case is returned to the dental
laboratory for further processing and therefore no historical record is
created. Additionally, these systems deal primarily with record keeping
functions and do not provide analytical tools that increase efficiency and
productivity and streamline the process flows of the dental laboratory.
Also, present systems deal primarily with single location dental
laboratories, and do not possess the ability to handle dental laboratory
enterprises comprising more than one main division and/or a plurality of
auxiliary divisions.
The system of the present invention is geared to the process or
manufacturing aspect of the dental laboratory business as well as record
keeping. Therefore, it is capable of providing a significant amount of
detailed and useful information regarding the process side of the dental
laboratory business that is unavailable on presently existing systems.
Because the system of the present invention considers so much detailed
information relating to the processing of cases in a dental laboratory, it
provides an analytic capability previously unavailable on other systems.
Specifically, the system of the present invention gathers and archives
pertinent information regarding processing of cases in a dental laboratory
including driver routing information necessary for case pickup,
information relating to the laboratory, division and department where the
work will be performed on that case, the process steps to be performed on
that case, the workstations at which work will be performed, the identity
of the technicians performing those steps, the elapsed time to perform
process steps, number of iterations for each case, and doctor's
preferences, the status of a case and other useful information.
Additionally, the dental laboratory can advise doctors who have work
pending in the dental laboratory when they can expect their cases back.
Because the system of the present invention is geared to the processing and
data storage aspect, it provides a means for tracking cases from pickup
through laboratory processing steps to delivery and invoicing. The system
of the present invention also serves as an analytical tool that may be
utilized by management to analyze collected data for the purpose of
improving productivity and efficiency and containing costs through
scientific management techniques. For example, using the information
gathered by the system of the present invention, dental laboratory
management can determine which doctor's cases are being worked on longest
by laboratory technicians and which laboratory technicians consume the
most time to finish work.
OBJECTS OF THE INVENTION
It is a general object of this invention to provide a computerized system
for managing cases in a dental laboratory which overcomes the
disadvantages of the prior art.
It is another object of this invention to provide an automated system for
tracking cases in a dental laboratory from pickup, through laboratory
processing steps to delivery and invoicing.
It is another object of this invention to keep track of historical
information for the purpose of increasing efficiency in the operation of a
dental laboratory.
It is another object of this invention to minimize errors associated with
automated case management systems through the use of bar-code printers and
hand-held scanners.
It is another object of this invention to increase the speed of processing
of dental laboratory orders.
It is another object of this invention to streamline the process flows
associated with a dental laboratory.
It is another object of this invention to increase the level of service
offered by a dental laboratory.
It is another object of this invention to provide accurate and timely
management information in order to increase efficiency.
It is another object of this invention to reduce the workload and manpower
requirements associated with the operation of a dental laboratory.
It is another object of this invention to provide a computerized system for
managing cases in a dental laboratory wherein said dental laboratory has
multiple divisions.
SUMMARY OF THE INVENTION
These and other objects of this invention are achieved by providing a
system for managing and analyzing the operation of a dental laboratory
engaged in the fabrication of dental appliances such as dentures, partial
dentures, implants, crowns, bridges and mouthguards at the prescription of
a dentist.
Fabrication of these appliances is achieved in a series of iterations, with
the first of these iterations occurring upon receipt of a prescription
from the doctor for fabricating an appliance. Subsequent iterations
include the return of the appliance by the doctor to the laboratory for
additional processing steps including try-in, finish, etc.
The system of the present invention comprises digital processing means,
data collection means, and data storage means. In the preferred
embodiment, the digital processing means comprises a plurality of
microcomputers located in various departments within the dental laboratory
that are linked in a network arrangement.
The data collection means, e.g., portable, hand-holdable bar-code scanners,
is arranged to collect process related data associated with each iteration
during the fabrication of each appliance.
The data storage means, e.g., a relational database, is arranged to store
the collected process related data associated with each iteration while
preserving previously stored data associated with prior iterations. The
system of the present invention makes available to dental laboratory
personnel data indicative of the history of the fabrication of the
appliance through all of the iterations. This information can be utilized
by dental laboratory personnel for analysis and for the effective and
efficient management of the laboratory.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a distributed data processing system for
managing and analyzing the operation of a dental laboratory in accordance
with the present invention;
FIG. 2 is an isometric view of one workstation forming a portion of the
system of the present invention;
FIG. 3 is an illustration of one particular screen display, i.e., the
Division Form screen display, produced by the software forming a portion
of the present invention;
FIG. 4 is an illustration of one particular screen display, i.e., the
Department Form screen display, produced by the software forming a portion
of the present invention;
FIG. 5 is an illustration of one particular screen display, i.e., the Case
Type Form screen display, produced by the software forming a portion of
the present invention;
FIG. 6 is an illustration of one particular screen display, i.e., the
Workstation Form screen display, produced by the software forming a
portion of the present invention;
FIG. 7 is an illustration of one particular screen display, i.e., the Case
Types To Process Types To Workstations Links screen display, produced by
the software forming a portion of the present invention;
FIG. 8 is an illustration of one particular screen display, i.e., the
Employee Form screen display, produced by the software forming a portion
of the present invention;
FIG. 9 is an illustration of one particular screen display, i.e., the
Doctor Form screen display, produced by the software forming a portion of
the present invention;
FIG. 10 is an illustration of one particular screen display, i.e., the
Locations Form screen display, produced by the software forming a portion
of the present invention;
FIG. 11 is an illustration of one particular screen display, i.e., the
Business Hours Form screen display, produced by the software forming a
portion of the present invention;
FIG. 12 is an illustration of one particular screen display, i.e., the
Territory Form screen display, produced by the software forming a portion
of the present invention;
FIG. 13 is an illustration of one particular screen display, i.e., the Ship
Via Form screen display, produced by the software forming a portion of the
present invention;
FIG. 14 is an illustration of one particular screen display, i.e., the Case
Type Preferences Form screen display, produced by the software forming a
portion of the present invention;
FIG. 15 is an illustration of one particular screen display, i.e., the Case
Type Workstation Preferences Form screen display, produced by the software
forming a portion of the present invention;
FIG. 16 is an illustration of one particular screen display, i.e., the
Product Code Form screen display, produced by the software forming a
portion of the present invention;
FIG. 17 is an illustration of one particular screen display, i.e., the
Billing Code Form screen display, produced by the software forming a
portion of the present invention;
FIG. 17a is an illustration of one particular screen display, i.e., the
Schedule Pick-up and Delivery Form, produced by the software forming a
portion of the present invention;
FIG. 18 is an illustration of one particular screen display, i.e., the Case
Entry Form screen display, produced by the software forming a portion of
the present invention;
FIG. 19 is an illustration of one particular screen display, i.e., the
Tooth Indicator Form screen display, produced by the software forming a
portion of the present invention;
FIG. 20 is an illustration of one particular screen display, i.e., the RX
(prescription) Detail Form screen display, produced by the software
forming a portion of the present invention;
FIG. 21 is an illustration of one particular screen display, i.e., the
Schedule Form screen display, produced by the software forming a portion
of the present invention;
FIG. 22A is a pictorial representation of a portion of the work ticket used
in accordance with the present invention;
FIG. 22B is a pictorial representation of a second portion of the work
ticket used in accordance with the present invention;
FIG. 22C is a pictorial representation of a third portion of the work
ticket used in accordance with the present invention;
FIG. 22D is a pictorial representation of a shipping label used in
accordance with the present invention;
FIG. 22E is a pictorial representation of an RX (prescription) return form
used in accordance with the present invention;
FIG. 23 is an illustration of one particular screen display, i.e., the Scan
Maintenance Form screen display, produced by the software forming a
portion of the present invention;
FIG. 24 is an illustration of one particular screen display, i.e., the
Workstation Logging Form screen display, produced by the software forming
a portion of the present invention;
FIG. 25 is an illustration of one particular screen display, i.e., the Case
Look-up Form screen display, produced by the software forming a portion of
the present invention.
FIG. 26 is a flow chart illustrating the operation of a bar-code scanner
used in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to various figures of the drawings where like reference
numerals refer to like parts, there is shown in FIG. 1, an embodiment of
the dental laboratory case management system 5 constructed in accordance
with this invention.
As is seen in FIG. 1 the dental laboratory case management system 5
comprises a plurality of networks 6 and 7, said networks being connected
by means of telephone lines 26 and a modem 8. Two networks, 6 and 7 are
depicted in FIG. 1 for purposes of illustration. It should be understood
that the system 5 of the present invention can be implemented as a single
network in a dental laboratory having a single location and,
alternatively, can be implemented as a plurality of any number of networks
where the dental laboratory comprises many divisions, one network being
located within one division and linked to other networks located at other
divisions by means of telephone lines 26 and modems 8. Each network
enables users on that network to share data stored on disks and files and
to share hardware devices such as laser printers 10 located on that
network in a manner that is known to those practiced in the art.
Still referring to FIG. 1, in the preferred embodiment described herein,
each of the networks of the system 5 of the present invention is organized
in an arrangement known by those practiced in the art as the client/server
architecture. Under the client/server architecture each network in system
5 comprises three components including a plurality of client workstations,
e.g., 14A through 14H, a server 16 and a communications channel 18. Those
practiced in the art are aware that under the client/server architecture,
computing tasks are evenly divided between the database server 16 and the
plurality of client workstations, e.g., 14A through 14H, to provide a high
level of performance, productivity and cost effectiveness.
In the preferred embodiment, network 6 of system 5 comprises eight client
workstations 14A through 14H located in and corresponding to various
departments of the dental laboratory. As shown in FIG. 1, a client
workstation 14A is located in the shipping and order entry department, a
client workstation 14B is located in the billing department, a client
workstation 14C is located in the inspection department, a client
workstation 14D is located in the customer service department, a client
workstation 14E is located in the production department, a client
workstation 14F is located in the accounting department, a client
workstation 14G is located in the marketing department, and a client
workstation 14H is located in the executive offices for use by management.
There is also shown a client workstation 19 located remotely at a
dentist's offices (to be discussed in further detail later in this
disclosure).
Referring now to FIG. 2, there is depicted any one of the plural client
workstations utilized in any one of the networks of the system 5 of the
present invention. Each client workstation serves as the interface between
the system 5 and the user. The client workstation is often a
microcomputer, e.g., personal computer. Microcomputers utilized as
workstations, e.g., 14A through 14H, in system 5 preferably possess an
80486 type microprocessor or faster and between eight and sixteen
megabytes of random access memory along with a mouse pointer 20, a
high-quality color monitor 22 and a high-quality keyboard 24.
In the preferred embodiment of the present invention, each of the client
workstations 14A through 14H may be equipped with any one of several
operating systems that enables the client workstation to communicate with
other workstations in the network and the server 16. Additionally, the
operating system of each client workstation provides a graphical user
interface (GUI) that enables users to interact with the client workstation
by means of a group of icons located on a bar at the top of the screen.
These icons are selected by the user by means of utilizing a mouse
pointer. One such product designed to be utilized by client workstations
in the client/server architecture and having both the networking and
operating system capabilities described above is sold under the name
WINDOWS FOR WORKGROUPS by Microsoft Corporation. WINDOWS is a trademark of
Microsoft Corporation.
The server 16 of each network of system 5 is an unattended microcomputer,
e.g., personal computer, preferably equipped with an 80486 microprocessor
or faster or any other microprocessor which will be compatible with the
operating system and a random access memory comprising sixteen or more
megabytes. Under the client/server architecture, each server 16
communicates with the client workstations, e.g., 14A through 14H, within
the server's network 6 and honors requests submitted by the client
workstations, e.g., 14A through 14H, for file operations such as printing,
opening and closing files and writing to files. The server 16 provides the
client workstations with shared access to disks, files and printers. The
server 16 may be equipped with any one of several operating systems that
enable it to communicate with the client workstations, e.g., 14A through
14H. One such operating system is sold under the name WINDOWS NT ADVANCED
SERVER by Microsoft Corporation. WINDOWS NT is a registered trademark of
Microsoft Corporation.
Additionally, the client/server architecture as disclosed in the present
invention exploits the benefits of a relational database that is resident
on the server 16 wherein information is stored in tables and formed into
relationships using links in a manner familiar to those practiced in the
art. The server 16 is provided with any one of several software packages
that enables users to enter, edit and retrieve data from the relational
database in response to requests from clients. One such relational
database management system software package particularly suited to perform
these tasks is sold under the name MICROSOFT SQL SERVER by Microsoft
Corporation.
Each network of system 5 provides a communications channel 18 between each
of the client workstations, e.g., 14A through 14H and the server 16. The
communications channel 18 consists of hardware including network adapter
cards (not shown), hub (not shown), cables (not shown) and software such
as a network operating system that enables the transmission and receipt of
data among all the client workstations, e.g., 14A through 14H, and servers
16 within respective networks, 6 and 7. Software and hardware particularly
suited to perform the networking task is sold under a variety of names,
including ETHERNET (.TM.) by Xerox Corporation.
The system 5 is to be implemented by a dental laboratory business
comprising one or several divisions. Typically, in the multi-divisional
dental laboratory, the headquarters operates at one location and one or
more divisions operate at remote locations. System 5 is to be utilized by
these multi-locational dental laboratory divisions by implementing one
network 6 described herein at the headquarters facility of the dental
laboratory to serve as the main network and connecting that network 6 to
one or more additional networks, e.g., 7, implemented at each of the
divisional operations. Linking of these networks, e.g., 6 and 7, is
implemented by means of conventional modems 8 and telephone lines 26 in a
manner that is familiar to those practiced in the art. One such software
package particularly suited to linking networks together by means of
modems and telephone lines is known as Remote Access Services. Remote
Access Services is a feature offered under the previously mentioned
WINDOWS NT ADVANCED SERVER by Microsoft Corporation. Additionally, as
shown in FIG. 1, the invention of the present application is intended to
be utilized in a manner that enables a doctor, e.g., dentist,
periodontist, endodontist, to obtain relevant information from the system
remotely by means of a client workstation 19, e.g., personal computer,
located in the doctor's office and connected to the system 5 through
telephone lines 26 and a modem 28.
Referring again to FIG. 2 there is depicted a pictorial representation of
the video display of one of the client workstations 14 of the present
invention.
For initial set-up of each of the client workstations, e.g., 14A through
14H, in the system, the user inserts one or several diskettes containing
workstation source code in slot 30 of the client workstation and is
presented with a screen display (not shown) prompting the user to input
certain information by means of the keyboard 24 and mouse pointer 20 to
enable copying of the application software package from the diskettes onto
the permanent memory of the workstation. This set-up procedure is repeated
by the user for each client workstation, e.g., 14A through 14H, in the
system 5.
Similarly, for initial set-up of each of the servers 16 in the system 5,
the user inserts one or several diskettes containing server source code of
the system 5 in the slot of the database server 16 and is presented with a
screen display (not shown) prompting the user to input information by
means of the keyboard 24 and mouse pointer 20 to enable copying of the
application software package from the diskettes onto the permanent memory
of the server. This set-up procedure is repeated by the user for each
server 16 in the system 5. In the preferred embodiment, the application
software of the present invention can be written in any one of a number of
suitable programming language products sold under various trademarks. Two
such programming language products are particularly suited for the system
of the present invention. One is sold under the Registered Trademark
VISUAL BASIC and the other is sold under the Registered Trademark VISUAL
C++, both by Microsoft Corporation.
When the set-up procedure has been completed, the software generates an
icon (not shown) on the screen display of monitor 22. When the icon is
selected by double-clicking the mouse pointer button 20, the system 5
prompts the user for a group of inputs enabling the user's access to a
client workstation, e.g., 14A through 14H, at which the user is located
and access the server 16.
Referring again to FIG. 1, the system 5 of the present invention is
equipped with various security levels to maintain the integrity of the
database resident on the server 16 within each network. In other words,
only designated personnel have access to all aspects of the system 5
including the ability to input and modify information in the database. On
the other hand, doctors who access the system 5 by means of a client
workstation 19 connected to the system 5 by means of modom 28 and
telephone lines 26 have only limited access to the system 5, i.e., they
are only able to view data and not modify or add data, except to schedule
pick-ups of cases from their office(s) and to add their "preferences",
e.g., that crowns be prepared with a stippled rather than smooth finish.
The designation of doctor preferences and scheduling pick-ups are features
of the system of the present invention which will be discussed in detail
later.
The case management system 5 of the present invention enables system users
to effectively manage the various steps involved in the processing of
cases in a dental laboratory from case origination through fabrication of
the final dental appliance. Additionally, the case management system of
the present invention enables dental laboratory management to perform
analytical functions such as the determination of labor costs by
calculating process times at various workstations and keeping track of
iterations, i.e., the number of times a case is returned by a doctor to
the laboratory for additional processing.
The fabrication of a dental prosthetic appliance, i.e., a case, can best be
described as an iterative process sometimes involving a few and more often
times involving many steps depending upon a variety of factors. That is,
when a dental prosthetic appliance created by the laboratory is initially
fitted into the patient's mouth, it is usually necessary for the dentist
to return that appliance to the dental laboratory for further processing
one or several times before that appliance is formed to achieve a suitable
fit within the patient's mouth.
For example, a dentist may recognize that a patient will benefit from the
use of a full upper and full lower denture. The dentist will first create
impressions of the patient's upper and lower dentition by using two dental
impression trays. Each dental impression tray is loaded with a suitable
setting impression material. The first dental impression tray is utilized
for creating an impression of the patient's upper dentition and the second
dental impression tray is utilized for creating an impression of the
patient's lower dentition. Each of the two dental impression trays is
loaded with impression material and sequentially positioned within the
patient's mouth. The patient bites into the impression material contained
within each tray to form an impression of the upper and lower dentition in
the patient's mouth.
After the material sets, the doctor sends the upper and lower impressions
to the dental laboratory with a set of instructions, commonly referred to
as an "RX" or prescription, to fabricate a "wax-up" denture based upon
these impressions. It is important to note that receipt by the dental
laboratory of the RX or prescription along with these impressions from the
doctor's office is considered to be the first "iteration" in the
processing of the case.
There are several steps involved in the fabrication of the wax-up denture.
First, upon receipt of the impression trays from the doctor's office, a
technician in the dental laboratory pours stone or plaster into the
impression trays to create two plaster models. Each of these plaster
models is used to create the dental prosthetic device that will be placed
into the patient's mouth to replace and simulate missing dentition.
The first plaster model represents a positive impression of the patient's
existing upper dentition. This plaster model shows the shape and position
of the patient's existing upper teeth and also shows where upper teeth are
missing. Likewise, the second plaster model represents a positive
impression of the patient's lower dentition. The second plaster model
shows the shape and position of the patient's existing lower teeth and
also shows where lower teeth are missing.
Once these plaster models are created, a step known as "articulation" is
performed. In articulation, the dental laboratory technician places the
two plaster models of the upper and lower dentition into a device commonly
known as an "articulator". Once placed into the articulator, the
technician can adjust the upper and lower plaster models to achieve proper
occlusion, i.e., proper relationship of the surfaces of the upper and
lower teeth when in contact with one another.
Once the plaster models have been articulated and proper occlusion has been
achieved, a step known as "set-up" is performed. During set-up, the dental
laboratory technician selects artificial teeth made from acrylic or
porcelain and using set-up wax, roughly places the artificial teeth in the
upper and/or lower plaster models at positions where the patient has lost
teeth. Set-up is performed while the upper and lower plaster models remain
positioned in the articulator. Again using the articulator to simulate the
opening and closing of the mouth, the technician determines that proper
occlusion is achieved with the selected artificial teeth positioned in the
plaster models.
Next, a step known a "wax-up" is performed. In wax-up, a technician
carefully applies wax over the artificial teeth in their set-up position
while in the articulator so as to create a wax-up denture. The wax-up
denture consists of the artificial teeth held in their positions by the
wax. This is the resulting wax-up denture that is returned to the doctor
for a trial fitting within the patient's mouth.
In particular once the doctor has received the wax-up, he/she will place
the device in the patient's mouth. This step is known as the first
"try-in". After observing the wax-up in the patient's mouth, the dentist
may determine that artificial teeth in the wax-up denture must be
repositioned by the dental laboratory. The doctor may deem it necessary to
make several other types of changes to the wax-up. If the doctor deems
that changes are necessary, he/she will return the case to the dental
laboratory with a prescription to make further modifications in order to
perform a second try-in in order to achieve a better fit. It is important
to note that receipt of the wax-up by the dental laboratory with another
prescription from the doctor is regarded as the second iteration in the
creation of the denture.
Many times, the doctor will determine that a third, fourth or fifth try-in
is necessary to assure a proper fit within the patient's mouth. Each time
the doctor returns the denture to the laboratory with a prescription for
further adjustments, another iteration occurs requiring additional
processing steps to be performed in the dental laboratory.
Once the doctor is satisfied that the wax-up fits suitably within the
patient's mouth, he/she returns it to the laboratory with another
prescription instructing the laboratory to make the final denture. This
adds another iteration in the processing of the case. To finish the
denture, the laboratory performs the step of "investing". This step
involves the placement of plaster around the wax portions of the wax-up
denture and placing the resulting product into a flask. A "boil-out" step
is then performed, whereby the wax is boiled away. Next, the denture is
packed with acrylic in a flask, cured under a heat polymerization system,
and "devested" i.e. removed. Next, the rough acrylic is finished with a
finishing bur, then polished to put a high shine on the denture. Finally,
the denture is disinfected.
Thereafter, the denture is returned to the doctor as the final denture. If
the doctor is satisfied with the fit of the finished denture within the
patient's mouth, no further iterations are necessary.
It is not unlikely that a particular case could go through as many as ten
iterations or more before being completed to the doctor's satisfaction.
Since many dental laboratories charge a fixed amount for the preparation
of various dental appliances, regardless of the number of iterations
needed to complete the case, as the number of iterations for a particular
case increases, labor and material costs increase and therefore profit
made by the dental laboratory on the case decreases. Thus, doctors who
return a given case to the laboratory for further processing a number of
times that is above average create higher costs for the laboratory and
thereby decrease the laboratory's profits.
Therefore, in order to minimize costs and thereby increase efficiency and
profit, it is in the dental laboratory's best interest to identify those
cases where excessive iterations have occurred and determine how to
eliminate these occurrences in the future. The case management system 5 of
the present invention enables dental laboratory management to do just this
by recording and archiving the number of iterations for each particular
case being processed. That is, if an unusually high number of iterations
are detected for a particular case, this may indicate that a particular
technician requires further training or that a doctor has been returning
cases where work has been satisfactorily been performed.
With each additional iteration, the system 5 of the present invention
collects and archives a wide range of process information related to that
specific iteration. Such process related information includes, but is not
limited to, the identification of the technician who worked on the case
during that iteration, the type(s) of process(es) performed, the division,
department(s) and workstation(s) wherein these processes were carried out,
the date, start time, finish time and elapsed time for performing each
process step, prescription information, and doctor information such as
name, telephone number, preferences and office hours.
As previously stated, prior art dental laboratory systems are geared
primarily toward the function of record keeping. Therefore, under these
prior art systems, all valuable historical information relating to the
processing of cases is overwritten each time the case is returned to the
dental laboratory for further processing. Conversely, under the system 5
of the present invention, the database retains all historical process
related information relating to each iteration in the life of a case. This
information remains resident in the system's database after the case has
been completed and can be utilized by dental laboratory management in a
number of different ways. In other words, under the present system 5, all
process related information is preserved.
By collecting and storing information relating to each iteration in the
lifecycle of a case, a comprehensive database or data warehouse of
important process-related information is amassed. This information can be
utilized by laboratory management in a number of different ways. Moreover,
the laboratory management can utilize the .system 5 of the present
invention to generate any one of various reports, e.g., comparative
reports, historical reports, time based reports.
For example, utilizing said process-related information, a report can be
generated to compare a selected group of technicians on the basis of
elapsed time spent in completing jobs. Another report can be generated to
compare a selected group of technicians on the basis of number of quality
control rejections. Another report can be generated to compare doctors on
the basis of number of times cases are returned to the laboratory for
further processing. Another report can be generated to compare particular
doctors on the basis of time taken before returning cases to the
laboratory for further processing.
Essentially, information collected and retained within the database of the
system of the present invention can be manipulated in any one of a myriad
of ways to generate reports summarizing desired information. Further,
information contained within the database can be utilized by dental
laboratory management to determine labor and material costs so as to
develop costing and pricing models for each specific dental laboratory
operation.
To utilize the system 5 of the present invention, users perform three
general functions: maintenance, processing of dental laboratory cases, and
the generation of reports utilizing gathered process related information
for use by management.
Under the maintenance function, the user adds records to the database and
establishes logical relationships between these records by inputting data
into a series of system generated forms. By inputting information during
maintenance, said information is established on the system 5 and does not
have to be retyped into the system 5 during the day-to-day processing of
cases in the dental laboratory.
On forms to be discussed in detail below, the system prompts the user to
assign unique identification numbers for various parameters within the
database during maintenance, e.g., divisions, departments, case types,
prescriptions, process types, workstations, doctors, locations, employees,
territories, shippers, and associate descriptive information with those
unique identification numbers.
For example, where a dental laboratory comprises multiple divisions located
in different cities a user may choose to designate the identification of
the various divisions based upon an abbreviated form of the city in which
the division is located. For example, the code WG may designate the
Division ID (identification) for a division located in Willow Grove, Pa.
The code PL may designate the Division ID (identification) for a division
located in Pleasantville, N.J.
Likewise, Department ID's (identifications) may be based upon an
abbreviation of the department description. For example, RECV could be
used to designate the Department ID (identification) for the receiving
department and ARTIC may be used to designate the Department ID
(identification) for the articulation department.
The system 5 automatically assign Case IDs (case identification) for each
of the various cases processed in the dental laboratory. The system also
prompts the user to input Workstation ID's (identifications) for the
various workstations located within each of the departments. By way of
example, typical Workstation ID's include RECV for receiving, ARTIC for
articulation, WAX-UP for wax-up, FINSH for finishing, PORBLDUP for
porcelain build-up, QC for quality control, PORGLAZE for porcelain glaze
and SHIP for shipping.
The related database records that are established during the maintenance
function are utilized on a daily basis during the processing function to
be described in detail below. Because data relationships have been
established during the maintenance function, the processing of
transactions steps is expedited in ways to be described later in this
specification,
To aid in the describing the nature and content of the maintenance function
of system 5, a walk-through of the various forms that appear on the
display screen of the client workstation during use of the maintenance
function follows.
A user wishing to review, update or add information to the system database
can do so by selecting the Maintenance option from a system generated main
menu bar. The system then displays a list of all forms under the
maintenance function. The user selects a form from this listing utilizing
the mouse pointer 20.
The function and operation of several of the forms under the maintenance
option will be described in detail below.
The Division Form 32 is displayed as shown in FIG. 3. In accordance with
the present invention, the purpose of the Division form 32 is to enable
the user to create and maintain within the database information relating
to particular divisions that comprise a multidivisional dental laboratory.
As shown in FIG. 3, the Division form 32 provides a plurality of fields,
each field pertaining to a particular attribute of that division, e.g.,
Division ID (identification) 34, division name 36, division address 38,
the name of the server 40 resident at that Division, and the identity of
the database 42 resident at that division. Additionally, a comment box 44
is provided on the Division Form 32 to enable the user to insert comments
about that division. By inputting the requested data on this form, the
user establishes links between information relating to divisions within
the lab.
To create new divisions within the database, the user clicks on the NEW
button (not shown) on the command ribbon of the operating system and
enters the information in the appropriate fields of the Division Form 32.
Other forms in the system similarly utilize the NEW button on the command
ribbon to create new records and the drop-down buttons located on the
various forms for reviewing and updating existing records.
Once the Division Form 32 has been completed with respect to one or more
divisions within the dental laboratory, the user can review and revise
information about any of the previously inputted divisions. By clicking on
the drop down button 33 located to the far right of the field labelled
Division ID 34, the system 5 displays a list of division identifications
previously inputted, each division identification representing a separate
division that has been previously created by the user in the database. By
clicking on any one of these displayed division identifications, the
system enters that division into the Division ID field and populates all
of the other fields on the Division Form 32 with information retrieved
from the database relating to that particular division. In this manner,
information about particular divisions can be reviewed, and updated as
needed.
The Department Form 46 is displayed as shown in FIG. 4. In accordance with
the present invention, the purpose of the Department Form 46 is to enable
the user to create, update and review information relating to each
department within each division of the dental laboratory. Fields are
provided to record this related information including department
identification 48, department name 50 and the name of the manager
supervising that department 52. Typical departments found in a dental
laboratory include shipping, receiving, acrylic, porcelain crown/bridge,
metal, orthodontics, implants, administration, inspection, billing, etc.
The user may create new departments in the system by utilizing the NEW
button located on the command ribbon and entering information into the
appropriate fields as previously described. The user can review and update
existing department records by clicking on the drop-down button 54 located
to the right of the Division ID field 56 and then clicking on any of the
displayed division identifications, the system 5 enters that division
identification into the Division ID field 56 and populates the rest of the
fields on the form with information retrieved from the database.
The Case Type Form 58 is displayed as shown in FIG. 5. A case type refers
to any one of the many different types of dental appliances fabricated in
a dental laboratory, e.g., dentures, partial dentures, implants, crowns
and mouth guards. In the Case Type Form 58, the user enters information
into fields about a new case type or updates and/or review information
about existing case types. Fields are provided to input case type
identification 60, case description 62, e.g., denture, partial denture,
mouth guard.
The Case Type Form 58 also provides fields for Process Type ID 64 and
Process Type Description 66. A process type includes all of the process
steps performed at workstations between iterations in a particular case.
For example, one process type referred to as finish denture to first
try-in stage includes all of the workstations at which work is performed
to prepare the wax-up denture for the first try-in, i.e., receiving, tooth
selection, articulation, set-up, wax-up, quality control and shipping. A
second process type, referred to as return from try-in, make changes for
second try-in, includes all of the workstations at which work is performed
to prepare the denture for the second try-in, e.g., set-up and wax-up
workstations. A third process type, referred to as return from try-in and
finish denture, includes all of the workstations at which work is
performed to prepare the final denture, e.g., investing, boil-out,
packing, curing, divesting, finishing, polishing, disinfecting, inspection
and shipping. As previously stated, each process type has an associated
Process Type ID 64 and Process Type Description 66. These attributes are
inputted into the database on the Case Type form 58.
By depressing the Workstations Button 67 located at the bottom center of
the Case Type Form 58, the user can gain access to the Workstations Form
68. The Workstations Form 68 is displayed as shown in FIG. 6. In
accordance with the present invention, the purpose of the Workstations
Form 68 is to enable the user to enter information relating to the
identification and description of each of the various workstations within
a department in the dental laboratory. These dental laboratory
workstations are to be distinguished from the workstations previously
discussed in this application in connection with client/server
architecture. Fields are provided on the Workstations Form 68 including
Division ID 70, Department ID 72, Workstation ID 74 and Workstation
Description 76. Typically, workstations within the dental laboratory are
manned by skilled technicians that perform specific processes on cases
sent to the dental laboratory by doctors. As previously stated, typical
workstations include RECV for receiving, ARTIC for articulation, WAX-UP
for wax-up, SET-UP for set-up, FINSH for finishing, QC for quality
control, PORGLAZE for porcelain glaze and SHIP for shipping.
Relationships between particular case types, e.g., dentures, their related
process types, e.g., first try-in, and the multiple workstations
corresponding to each process type is established in the database through
the use of the Case Type To Process Type To Workstation Links Form 78
shown in FIG. 7. The user enters the case type identification in the Case
Type ID field 80, the process type identification in the Process Type ID
field 82 and the division identification 84, department identification 86,
the workstation identification 88 and the workstation description 90 into
the appropriate fields.
The Employee Form 100 is displayed as shown in FIG. 8. In the Employee Form
100, the user can enter information about new employees or review and/or
update information about existing employees that work in a department of a
division of the dental laboratory. As shown in FIG. 8, the Employee Form
100 displays information including the employee's name, address, social
security number, employee identification number, the department in which
that employee works and other related information.
Utilizing additional forms, the system stores additional detailed
information relating to the operation of the dental laboratory. On the
Doctor Form 110, shown in FIG. 9, the user can input data pertaining to
individual doctors who send work to the dental laboratory for processing.
As shown in FIG. 9, the user can input data on the Doctor Form 110
including the doctor's full name, territory, license number, doctor's
social security number and birth date, and terms of payment made by the
doctor to the dental laboratory.
The Locations Form 120, shown in FIG. 10, is related to the Doctor Form
110. On the Location Form 120 the user can input or review information
relating to the various office locations at which a doctor works including
Doctor ID, doctor's full name, Location ID, location name, addresses,
phone number, fax number, contact person's name, shipper's name, pick-up
and delivery preferences, vacation start and end dates and comments. In
this regard, it is not unusual for a doctor to conduct his own practice at
a first office location, work for another doctor at a second office
location and teach students at a university medical school where office
facilities are provided by the university for the doctor's use. By
utilizing this screen, user's of the system 5 may obtain information
regarding each of a doctor's multiple offices.
By clicking on the Business Hours button 122 appearing in the lower
right-hand corner of the Locations Form 120, the system 5 generates the
Business Hours Form 130 as shown in FIG. 11. The Business Hours Form 130
enables the user to input or review information regarding the hours of
operation for the various offices at which a doctor works as set forth in
the Locations Form 20. The Business Hours Form 130 also enables the user
to schedule the pick-up of cases from the doctor's office and delivery of
processed cases to the doctor's office at times when the doctor is in at a
particular office location.
On the Territory Form 140, shown in FIG. 12, the user can input information
relating to the description of the territory assigned to particular dental
laboratory drivers. The driver's identity may also be inputted on the
form.
In circumstances where a doctor's office is beyond the territory of the
dental laboratory, e.g., out of town, the laboratory typically ships cases
to doctors and receives cases from doctors by means of any one of a number
of outside courier services. The Ship Via Form 150, shown in FIG. 13,
enables the user to record in the database information relating to the
various outside couriers utilized by the dental laboratory for pick-up and
delivery of cases. Such information includes the identity of the courier,
telephone number, account number and comments including the type of
shipping used, e.g., economy or overnight delivery.
On another form, known as the Case Type Preferences Form 160, shown in FIG.
14, the user can input the preferences of individual doctors regarding the
processing of their cases. For example, a dental laboratory is typically
comprised of several departments. One department may perform all of the
work relating to acrylics and another may perform all work relating to
crowns. A third department may do all metal work and a fourth may do all
the porcelain work. Particular doctors may have specific preferences
regarding how they want their cases processed in one or several of these
various departments. One doctor may prefer that crowns be prepared with a
stippled surface, while another doctor may prefer a smooth finish. The
system of the present invention is utilized to designate what preferences
doctors desire with regard to the preparation of their cases, e.g.,
finishes on crowns.
Additionally, the Case Type Workstation Preferences Form 170, shown in FIG.
15, can be utilized by dental laboratory management to implement a
doctor's preferences at a particular workstation. For example, in creating
an acrylic denture, the case must be routed to a number of different
workstations within the acrylic department where different steps in the
manufacturing process are performed. In the system of the present
invention, specific information regarding a doctor's preference regarding
how work is performed on a case at a specific workstation may be provided
to a technician.
Another form under the maintenance function is known as Moulds and Shades
Form (not shown). The Moulds and Shades Form enables the user to specify
the exact shading and mould of artificial teeth to be selected and used by
technician during the preparation of dentures or crowns. The user makes
the selection of moulds and shades in response to a doctor's prescription.
This ensures that artificial teeth selected complement a patient's
existing teeth in an aesthetically pleasing manner.
A Products Code Form 180, shown in FIG. 16, is utilized for the purpose of
storing information about the various materials purchased by the dental
laboratory and used in the preparation of cases. For example, in order to
fabricate a denture, it is necessary for the dental laboratory to purchase
various materials from outside manufacturers, such as artificial teeth, in
order to build the denture. Cost information regarding these materials is
stored on the Product Code Form 180 and includes product code, product
description, Product Class ID, product price, raw material cost, part
number, product manufacturer, billing information and product notes.
Utilizing the information inputted in the Product Code Form 180, the system
5 of the present invention generates a composite list of the various raw
materials utilized by the dental laboratory in the preparation of cases
and their associated costs. This information, i.e., the raw material and
its associated cost, is contained in a product code bar code label. During
the processing of cases, the product code bar code labels are scanned by
the technician utilizing optical scanners to be discussed later in this
application.
A Billing Codes Form 190, shown in FIG. 17, enables the user to determine
the percentage of the total charge that a doctor will be charged for work
performed by the laboratory. In some instances, for example, a doctor may
return a case to the dental laboratory to be redone on the basis that the
work initially performed by the laboratory is unsatisfactory as the result
of poor workmanship or an original impression inaccuracy created by the
doctor. In such instances, the dental laboratory may determine that it is
appropriate to perform the rework, free of charge or for a percentage of
the full amount to perform the work. The Billing Codes Form 190 enables
the dental laboratory to generate a bill for any percentage, i.e., zero to
one-hundred percent, of the full amount charged to the doctor.
The second general function performed by the system 5 of the present
invention is the day-to-day management of the processing of cases in a
dental laboratory. In processing cases, the system of the present
invention performs a variety of tasks including the entry of case
information into the system, the scheduling of work to be performed by
technicians in the dental laboratory, the scheduling of case pick-ups from
dentists' offices and the delivery of finished or partially finished cases
to dentists' offices, the creation of invoices for completed work,
maintenance, printing, driver routing, the posting of invoices to
financial software packages and other functions.
Because much of the information needed to complete the forms associated
with the processing of transactions has been previously input by case
entry personnel during the set-up and maintenance function, minimal
additional information needs to be inputted by the user during the
day-to-day processing of transactions, thereby increasing efficiency. In
other words, much of the information does not have to be re-keyed and will
be displayed by the system 5 based upon previously completed forms during
the maintenance function of the system 5.
The Case Entry Form 200 is displayed in FIG. 18. The Case Entry Form 200 is
completed by case entry personnel when the dental laboratory initially
receives a new case from a doctor and each time that case is returned to
the dental laboratory for further processing.
As previously discussed, where a new case is being originated, the dental
laboratory will receive materials from the doctor, such as an impression
(in the case of a denture) and a prescription requesting that certain work
be done, e.g., finish denture to first try-in stage. Upon receipt of those
materials and prescription from the doctor's office, case entry personnel
enter the necessary information onto the Case Entry Form 200.
On the Case Entry Form 200, the Creation Date field is automatically filled
in with the current system date. As previously stated, much of the data
entered into the fields on the Case Entry Form 200 is inputted by case
entry personnel by clicking on various drop-down and zoom buttons
appearing on the Case Entry Form 200 and making selections from system
created lists, e.g., lists of Doctor ID, Case ID, Shades, Moulds, and
Status. Additionally, case comments can be inputted here.
If the case is initiated for the first time, the system automatically
assigns a new Case ID. To complete other fields on this form, the order
entry clerk types the information directly into the field.
It is important to note that where a case is being originated, no
information appears in the RX History Group Box 202. It is not until the
RX Detail Form 220, shown in FIG. 20, is completed at least once by case
entry personnel that information will appear in the RX History Group Box
202. The RX Detail Form 220 will be explained in detail below. Suffice it
for now to say that each time the case is returned to the dental
laboratory for further processing, case entry personnel will complete the
RX Detail Form 220 by recording information relating to that particular
iteration. Each time the RX Detail Form 220 is again completed, another
line item of information is automatically added to the RX History Group
Box 202 of the Case Entry Form 200.
It is also important to note that each time a case is returned for further
processing and case entry personnel again complete the RX Detail Form 220,
all process-related information inputted on previous RX Detail Form s 220
is retained and archived in the system 5 in order to create a database of
information to be utilized by management.
In this regard, by simply looking at the number of entries made in the RX
History Box 202 management can determine the number of iterations that
have occurred for a particular case. Each line item in the RX History Box
202 represents a single iteration. The RX History Box 202 provides
information including RX ID, Receipt Date, Ship Date and Remarks.
By monitoring iterations, management can reduce costs in ways previously
discussed. By determining the number of iterations for particular case
types, management can collect historical data and thereby establish an
average number of iterations needed to finish particular case types. Cases
that exceed the average number of iterations can be brought to
management's attention and studied to determine the reason why the average
number of iterations was exceeded. In one scenario where excessive
iterations are identified, the doctor may have sent the case back for
further processing as the result of unsatisfactory work performed by
technicians. In this instance, corrective action, such as additional
operator training may be necessary. In this manner, costs can be more
aggressively reduced resulting in greater profits for the dental
laboratory.
In another scenario, a particular doctor may habitually send work back to
the dental laboratory to be redone despite the fact that the work was
performed satisfactorily in the first place. The system 5 of the present
invention enables the user to identify such doctors in order to reduce
costs associated with unnecessary rework.
By clicking on the Teeth Button 208 appearing in the lower right-hand
corner on the Case Entry Form 200, the system 5 generates a visual
representation of the mouth, as seen in the Tooth Indicator Form 230 shown
in FIG. 19. The Tooth Indicator Form 230 enables case entry personnel to
utilize the mouse indicator 20 to indicate the areas or teeth on which
work is to be performed in a particular case. Case entry personnel may
also indicate whether a tooth is a pontic, i.e., an area where a tooth
must be replaced, or an abutment, i.e., an area where a tooth has been cut
down to support a crown or bridge.
By clicking on the RX Detail Button 204 from the Case Entry Form 200 (FIG.
18), case entry personnel can activate the RX Detail Form 220 shown in
FIG. 20. The RX Detail Form 220 is utilized for several purposes. First,
case entry personnel can specify the delivery location 212 and the
delivery due date and time 214 requested by the doctor. Additionally, case
entry personnel can specify the pan number 216 identifying the pan into
which materials received from the doctor were placed and the actual date
on which the completed case was return shipped 218 to the doctor. The
Receipt Date field 220 of the RX Detail Form 210 is automatically
populated by the system based upon the current system date. By clicking on
the Remake Box 232 on the RX Detail Form 210, case entry personnel can
designate whether the doctor's prescription calls for a remake. Each time
the RX Detail Form 210 is completed, a new RX identification number is
generated by the system 5 and an additional line of information is
included in the RX (prescription) History Box 202 (FIG. 18). As previously
stated, each time a new case is received by the dental laboratory and each
time a case is returned for further processing, the RX Detail Form 220 is
completed by case entry personnel. All information inputted on earlier RX
Detail Form s 220 is preserved in system 5 rather than being overwritten.
By clicking on the RX Image button 234 appearing on the RX Detail Form 220,
case entry personnel can view a computer generated image (not shown) of
the paper prescription form filled out and sent to the dental laboratory
by the doctor. The paper prescription sent in by the doctor must be first
scanned into the system for the image to be generated.
By clicking on the Schedule Button 236 located on the RX Detail Form 210,
case entry personnel can activate the Schedule Form 240 in order to
schedule work to be performed in the dental laboratory for particular
types of cases, e.g., crowns, bridges, implants, dentures, or partial
dentures and based upon the stage toward completion. The Schedule Form 240
is shown in FIG. 21. Specifically, once a user has selected an appropriate
case type and process type for a particular case, the system automatically
populates several of the boxes within the Workstations Box of the Schedule
Form 240 with information relating to the processing of that case.
This system generated information contained within the Workstations Box
includes the sequence of process steps, the various workstations at which
these steps will be performed, the estimated start time, estimated finish
time, actual start time and actual finish time. The estimated start and
finish times are based upon predetermined estimates inputted in the system
during set-up and maintenance. The relationships between case types,
process types and workstations has been previously established in the
system by completion of forms during maintenance, e.g., the Case Types
Form 58 shown in FIG. 5 and Case Types To Process Types To Workstation
Links Form 78 shown in FIG. 7.
By clicking on the Print Labels Button 242 on the RX Detail Form 210, the
system 5 generates a work ticket 248, a shipping label 250 and an RX
(prescription) return form 252 as shown in FIGS. 22A through 22E.
A new work ticket 248, shipping label 250 and RX (prescription) return form
252 is generated each time a new case is received by the dental laboratory
and each time a case is returned to the dental laboratory for further
processing. The work ticket 248, shipping label 250 and RX return form 252
remain with the case during all processing steps.
Referring to FIG. 1, the work ticket 248, shipping label 250 and RX
(prescription) return form 252 are printed on a dedicated bar code printer
10 located within network 6. It is preferred that thermal printers or
laser printers be utilized for the printing of labels containing bar codes
in the present system rather than dot matrix printers because thermal or
laser printers render a higher quality more readable bar code than dot
matrix printers. Bar coded data described in this disclosure is configured
in accordance with Code 128 which is a standard bar code symbology.
As shown in FIGS. 22A through 22C, the work ticket 248 of the present
invention is shown as comprising three labels: Label #1 shown in FIG. 22A,
Label #2 shown in FIG. 22B and Label #3 shown in FIG. 22C. Each label of
work ticket 248 contains various types of information. However, it should
be understood that the information contained on Label #1, Label #2 and
Label #3 of work ticket 248 could be combined and contained on a single
work ticket 248 for the purpose of convenience and simplicity.
As shown in FIG. 22A, Label #1 of the work ticket 248 displays information
including Doctor ID, Doctor's Name, Case ID, RX ID, Case Type ID, Process
Type ID, Division ID, Department ID, Pan No., Creation Date, Receipt Date,
Due Date, Case Comments, RX Comments, Material Comments and Case Type
Preferences.
As shown in FIG. 22B, Label #2 of the work ticket 248 displays the Doctor
ID, Doctor's Name, materials received from the doctor's office, and a bar
code label containing the Case ID and RX ID information.
As shown in FIG. 22C, Label #3 of the work ticket 248 contains two bar code
labels. Each bar code label contains the Workstation ID of a different
workstation at which work is to be performed by a technician. It should be
understood that Label #3 can contain one or more bar codes depending upon
the number of workstations at which work must be performed when a case is
sent to the dental laboratory for processing.
For example, a case may be sent to the dental laboratory by the doctor's
office for processing including articulation, wax-up and finishing. Each
of these processing steps is performed at a different workstation having a
different Workstation ID. Since the case is going to be processed at three
workstations, prior to processing, the case entry personnel would prepare
Label #3 to contain three bar codes: one designating the Workstation ID
for articulation, one designating the Workstation ID for wax-up and one
designating the Workstation ID for finishing.
Once the case has been received at the articulation workstation, the
technician passes an optical scanner 253 to be explained in further detail
below, over the bar code found on Label #2 in order to input the Case ID
and RX ID into the system 5. Next, the technician passes the optical
scanner 253 over the bar code found on Label #3 designating the
Workstation ID for articulation, to signal to the system that the
articulation step has begun. This is known as a start process scan. Once
the articulation step has been completed, the technician will again pass
the optical scanner 253 over the bar code found on Label #3 designating
the articulation workstation to signal to the system that the articulation
step has been completed. This is known as an end process scan.
The case is then transferred to the wax-up and finishing workstations where
the identical bar code scanning procedure is followed.
Information contained on Label #1, #2 and #3 of work ticket 248 has been
previously specified by case entry personnel during completion of forms
previously discussed, e.g., the Case Entry Form 200 shown in FIG. 18 and
the RX Detail Form 210 shown in FIG. 20.
The RX (prescription) return form 252, shown in FIG. 22D, is generated by
case entry personnel each time the case is returned to the dental
laboratory for additional processing. Once the RX (prescription) return
form 252 is generated, it is accumulated with the case and remains with
the case during processing and stays with the case when it is shipped to
the doctor's office.
As shown in FIG. 22D, the RX return form contains specific information
about the case including the return address of the dental laboratory, the
Division name, Doctor name, Case ID, RX ID, Patient Name and Preferences.
This information is printed on the RX Return form and is also contained in
a bar-code label that appears at the top of the RX return form 252.
The RX (prescription) return form 252 is provided with an adhesive back and
is intended to be affixed by doctor's office personnel to the exterior of
the shipping box containing the case when the case is returned to the
dental laboratory for additional processing. When the case is received by
the dental laboratory, information relating to said case can easily be
inputted into system 5 by case entry personnel by scanning the bar code
located at the top of the RX (prescription) return form 252.
It is important to note that scanning of the RX return form 252 signals to
the system 5 that another iteration has occurred. In other words, each
time an RX return form 252 is scanned for a particular case, a new line
appears under the RX History Box 202 of the Case Entry Form 200 shown in
FIG. 18.
The Shipping Label 250 shown in FIG. 22E, is created by case entry
personnel once a case is received by the dental laboratory. The Shipping
Label 250 is intended to be utilized by the dental laboratory for shipping
the case to the doctor's office after completion of processing. The
Shipping Label 250 contains a bar code encoded with information relating
to the case. Once the Shipping Label 250 has been scanned, along with all
other previous scans, the system is alerted to the fact that the case is
ready to be shipped.
Referring again to FIG. 1, in accordance with the present invention,
hand-held optical scanners 253 are utilized by technicians to read the
previously mentioned bar code labels contained on work tickets 248, return
labels 252 and shipping labels 250 for recording vital information during
the processing of cases through the dental laboratory. One such hand-held
optical scanner particularly suited to perform the function of scanning
bar codes is sold under the name Microwand III Interface Hand-Held Bar
Code Scanner manufactured by Hand Held Products, Inc, model number 32ES.
The hand-held optical scanner 253 is provided with an 80386 microprocessor
or faster, 512 kilobytes of memory or more and software (hereinafter
referred to as the "scanner software") enabling the scanner 253 to collect
data from the various bar codes previously described in this disclosure,
e.g., work tickets 248, RX (prescription) return labels 252 and shipping
labels 250 and to upload said data to the server 116 in a flat ASCII form
at using a standard communications protocol. The scanner 253 uploads data
to the server 116 by means of a docking station 260. The scanner 253 is
also provided with rechargeable batteries so that it can be portable and
therefore may be utilized at various workstations within various
departments of the dental laboratory.
The scanner 253 is provided with a liquid crystal display (LCD) which
displays information prompting a user to input specific information by
scanning or keying.
In accordance with the present invention, the scanner software enables the
scanner to collect data scanned by various technicians and keep separate
in its memory data collected by each of those multiple technicians. This
capability makes it unnecessary to provide each workstation in the dental
laboratory with its own dedicated scanner. In accordance with the present
invention, one or several of these scanner 253 are positioned within each
of the departments in the dental laboratories, e.g., production,
inspection and shipping and receiving.
Referring now to FIG. 26, the scanner software enables the scanner .253 to
perform seven types of scans: a start process scan, a product scan scan, a
quality scan, a ship scan, an end process scan, an upload data scan and a
close out scan.
As shown in FIG. 26, the scanner will first display an initialization menu
prompting the technician to input his or her identification number. The
technician may input the employee identification number by scanning or
alternatively, the technician can key this information into the system 5
manually. Once the technician's employee identification number is
inputted, the scanner 253 displays the internal date and time. The
accuracy of the date and time is to be verified by the technician before
performing any scans. Each time a technician perform s a scan, the scanner
software will automatically associate with that scan the exact time and
date at which the scan was perform ed.
Once the technician has verified the accuracy of the internal time and date
displayed on the scanner 253, the scanner will display a menu of scan
options including: start process scan, product scan, quality scan, ship
scan, end process scan, upload data scan and close out scan. The operator
perform s a start process scan upon beginning work on a particular job and
an end process scan when the work has been completed at that particular
workstation.
The start process scan consists of two modes, single case and batch mode.
As should be appreciated by those skilled in the art, in the dental
laboratory, certain processes may be perform ed more efficiently by
processing groups of cases simultaneously in batch mode rather than
sequentially. One such operation, e.g., the pouring of stone or plaster
into impression trays to create plaster models, may be perform ed more
efficiently by preparing an amount of stone or plaster to be poured into a
batch of cases rather than preparing a new amount to be poured into each
case individually.
In the single case mode, the scanner 253 will prompt the technician for
Case ID and RX ID then workstation information which will be time and date
stamped. Batch case mode will enable the scanner 253 to scan multiple
cases until ended by a key press. This information is then time and date
stamped.
The end process scan is identical to the start process scan and is perform
ed when processing has been completed at a particular workstation. The
scanner 253 is equipped with internal software enabling it to keep track
of elapsed time between the start process scan and the end process scan.
The scanner 253 gathers start process, end process, elapsed time, Case ID
and RX ID under a scan serial number and stores this information in the
internal memory of the scanner 253.
The product scan function will prompt for the Case ID and the RX ID to be
scanned then the product code and the bill code. All data to be collected
can be scanned or manually entered. The quantity is then entered. If the
product is a metal, the scanner will prompt for a weight value after the
quantity is entered. The scanner 253 then internally dates and time stamps
and stores the product scan. Each of the various product codes are found
on a set of bar code labels in a binder located at the operator's
workstation.
Once processing on a case has been completed, it is sent to quality control
for inspection. If that particular case passes inspection, the quality
control operator perform s a quality control scan, i.e., the inspector
waves the scanner 253 over a bar code (not shown) to indicate the case has
passed quality control inspection and is ready for shipping.
After the quality control scan is completed, the case moves to shipping.
The shipping scan is perform ed by scanning the bar code contained on the
Shipping Label 250 described above. Once the Shipping Label 250 has been
scanned, the case is considered ready to be shipped.
As shown in FIG. 26, before a second technician may utilize the scanner 253
to perform scans, the first technician must perform a close out scan to
terminate that technician's session. By performing the close out scan, the
first technician resets scanner 253 for use by the second technician.
Thereafter, a second technician can perform scans as previously described.
When the second technician obtains the scanner 253 he will be instructed
to first enter his or her employee identification number before performing
any scans. The scanner 253 will also be closed out prior to uploading any
information to the database on system 5. This will ensure that scanned
data will remain associated with the proper technician.
At the end of each workday or during the day, each scanner 253 is attached
to a docking station 260 as shown in FIG. 1. The purpose of the docking
station is to facilitate the uploading of data collected by the scanner
253 during the day into the database located on the server workstation 16.
The docking station 260 is often a microcomputer, e.g., personal computer.
Microcomputers utilized as docking stations 260 in accordance with this
invention preferably possess an 80486 type microprocessor or faster and
between eight and sixteen megabytes of random access memory. Each day, the
workstation server 16 incorporates those scanner 253 scans perform ed that
day with existing information on the database.
It is important to note that the various scans that are perform ed using
the scanner 253 as the case is processed in the dental laboratory are
archived in the database of the system 5 rather than being overwritten.
The various scanner 253 scans perform ed throughout the processing of a
case are displayed on the Scan Maintenance Form 280 shown in FIG. 23. By
entering search criteria, i.e., Case ID, Scan Type, Department ID,
Employee ID and date range, and clicking on Search 281, the system enables
the user to determine the status of a case by reviewing the scans perform
ed. The Scan Maintenance Form 280 lists information relating to each scan
perform ed on a particular case including the scan type, the date on which
the scan was perform ed, the department where the scan was perform ed, the
identification of the employee that perform ed the scan. In this manner,
management can determine the location of any case on the laboratory floor
at any particular time. Therefore, the Scan Maintenance Form 280 serves as
a tool for management to determine how close to completion a particular
case is and tells management what workstation and operator are presently
working on the case. In response to a doctor's request, the laboratory can
determine whether that doctor is going to receive the case from the dental
laboratory by the date requested.
The user can access the Workstation Logging Form 290, shown in FIG. 24 from
the maintenance menu. By entering search criteria, i.e., Division ID, Case
ID, RX ID, Case Type ID, Workstation ID, and Employee ID, the system will
display in the Time Spent Box 291 the elapsed time taken by an identified
operator to complete a specific task on the shop floor. The elapsed time
provided by the system 5 provides a tool for management to review the
actual elapsed time for technicians to perform specific tasks in the
dental laboratory.
By keeping historical records of elapsed times and utilizing statistical
methods, management can establish control parameters or average times. An
operator's performance can be compared against these control parameters to
determine whether that operator is performing exceptionally,
satisfactorily or unsatisfactorily. Instances where an operator's time
falls below the established control parameters can be identified by
management and corrective action can be taken where necessary. Such
corrective action may include additional operator training or the
conducting of studies to determine improved methods. The use of scientific
management techniques will increase productivity. Finally, by determining
actual process times for each case type, management is able to determine
labor costs and therefore can more effectively determine pricing.
The Schedule Pick-up and Delivery Form 194 is displayed in FIG. 17a. The
purpose of the Schedule Pick-up and Delivery Form 194 is to enable the
entry of numerous details regarding the doctors' requests for pick-up and
delivery of his or her cases. Scheduled pick-ups of cases from the
doctor's office can be initiated by the doctor calling the dental
laboratory or pick-ups can be scheduled in the system to be recurring at
specific times and days. The Schedule Pick-up and Delivery Form 194 is
also utilized by the dental laboratory to ship finished or partially
finished cases back to the doctor's office. The Schedule Pick-up and
Delivery Form 194 is completed by clicking on the various drop-down
buttons located on the form and making selections for the various
parameters set forth on the form , e.g., Division ID, Doctor ID, Location
ID, Case ID, RX ID, Ship Via, Territory, Estimated Arrival Time, Requested
Arrival Time. However, shipping is automatic based upon the case delivery
date specified by the doctor.
The Case Look-up Form 300 is shown in FIG. 25. A doctor may obtain limited
access to the system of the present invention by means of connection
through a computer and a modem line. Doctors may utilize the Case Look-up
Form 300 to determine the status of cases they have sent to the dental
laboratory for processing. The doctor may enter search data such as the
case identification, doctor's last name, doctor's telephone number,
patient's last name or any combination and clicking the Search Button 302
to search for a desired case. Boxes contained within the Case Look-up Form
300 are then populated by the system that match the search criteria with
the most recent case being highlighted. The doctor can then select a
different case if desired. Once the desired case is selected, the user can
view the prescription history by clicking on RX Detail (previously
described). Doctors utilizing the Case Look-up Form 300 can also specify
preferences.
Without further elaboration, the foregoing will so fully illustrate my
invention that others may, by applying current or future knowledge, adapt
the same for use under various conditions of service.
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